Stop valve

ABSTRACT

A stop valve includes a valve body, a multi shot resilient control sleeve, O-ring and handle. The control sleeve is molded to the valve stem to create an integral but separately molded fluid control member. Inlet line pressure resiliently biases the side walls of the control sleeve and a circumferential sealing flap formed thereon into sealing engagement with the valve bore to prevent leakage. The control sleeve consists of a hard plastic cylinder and a flexible barrel member molded as one consistent piece by a multishot molding process. The O-ring also serves as a backup seal to prevent leakage to atmosphere. A valve handle is secured to the valve by either a screw or a snap protrusion.

RELATED APPLICATIONS

This application claims priority from U.S. Provisional Application No.60/400,280 filed on Jul. 31, 2002.

BACKGROUND OF THE INVENTION

I. Field of the Invention

A stop valve for controlling the flow of fluid through fluid lines and,in particular, to a stop valve manufactured through a multi-stagemolding process to include a sealingly resilient fluid control sleeveand a more rigid valve stem for rotation of the sleeve.

II. Description of the Prior Art

A stop valve is a shut-off valve to permit the replacement of washers orother repairs to be accomplished on a plumbing fixture without shuttingdown an entire plumbing system. The stop valve is commonly located inthe fixture supply line between a wall and the fixture. Stop valves aregenerally available in two basic styles. One style is known as an anglestop valve that has the inlet and outlet of the valve at right angles toeach other. The other standard configuration is a straight-througharrangement wherein the inlet and outlet are coaxially aligned with eachother.

One type of effective and efficient angle stop valve is disclosed inU.S. Pat. Nos. 4,562,994 and 4,609,177 to Turner et al and incorporatedherein by reference. Another example of an angle stop valve is disclosedin U.S. Pat. No. 5,076,540 to Murphy and No. 5,695,169 to Higgins.

In all of these previous disclosures, the stop valve has a controlsleeve made from low friction resilient thermoplastic material such as aSantoprene™ material. The handle is formed from a durable plasticmaterial such as ABS. The operation of the valve from the open to theclosed position is a simple quarter turn of the handle. The resilientplastic material of the valve control sleeve provides for a completeshut off of the water supply. As with all stop valves, these plasticstop valves may be left in the open position for many months and evenyears without being touched. The long period of time between use of theshut off valve allows for significant mineral deposit on the valve whichmay bind the valve within the valve body. The resulting bindingnecessitates the use of increased torque to be applied onto the valve tobreak the binding layer of mineral deposits in order to move the valveto the closed or shut off position. Additionally, stops need to beresistant to oxidative agents, freezing conditions and aggressive waterconditions. Prior inventions containing a single plastic control sleevecould not provide sufficient performance under all water conditions. Thetorque required to break these binding barriers sometimes caused thevalve stem to break, twist like a screw, or disconnect from the controlsleeve leaving no means for closing the stop valve. The presentinvention overcomes the disadvantages of the prior known stop valves byusing a multishot molding process to provide a control sleeve that has aflexible wall in the sealing area and a hard plastic stem for mechanicalcontrol.

SUMMARY OF THE INVENTION

The present invention overcomes the disadvantages of the prior knownstop valves by using a multishot molding process to provide a controlsleeve that has a flexible wall in the sealing area and a hard plasticstem for mechanical control.

In accordance with one aspect of the present invention, a plumbing valveincludes a valve body having an inlet and an outlet. The flexible memberof the resilient control sleeve is located within the valve body forrotation between an open and closed position. The sleeve is open at itsaxial inlet end and has a side wall of circular cross-section extendingbetween the open inlet end and the end wall. The side wall has at leastone outlet port in fluid communication with the inlet end. The sleeveside wall is contoured and dimensioned to be snugly but rotatablyreceived within a receiving bore of the valve body for opening andclosing the valve.

The closed end wall of the control sleeve has a hard plastic handleengaging stem section axially extending therefrom. The handle engagingstem section includes a geometric shape which mates with the handle. Thehandle stop rotation can be attained by either a corresponding geometricshape in the body or a protrusion from the body that mates with anintegral feature of the handle. Desirably, the handle has a firstannular section with internal geometric cross section that mates withthe hard plastic section of the control sleeve. The handle is secured tothe control sleeve by either using a fastener or mating the handle witha protrusion on the rigid stem.

In accordance with a preferred embodiment of the stop valve, the rigidvalve stem facilitates the application of sufficient torque to break thebinding forces sometimes found in such valves. Further, the softermaterial used to mold the control sleeve provides a sealing resilienceto prevent fluid leakage past the control sleeve. The multi-shot moldingprocess allows the valve stem to be molded to the previously moldedcontrol sleeve. Additional molding steps can be used to mold a lockingretainer to the valve member and seal members which amount to integralO-ring seals.

Other objects, features and advantages of the invention will be apparentfrom the following detailed description taken in connection with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWING

The present invention will be more fully understood by reference to thefollowing detailed description of a preferred embodiment of the presentinvention when read in conjunction with the accompanying drawing, inwhich like reference characters refer to like parts throughout the viewsand in which:

FIG. 1 is a perspective view of a multi-shot molded valve cartridgeaccording to the present invention;

FIG. 2 is a cross-sectional view of an angle stop valve embodying thepresent invention;

FIG. 3 is a cross-sectional view of a straight stop valve embodying thepresent invention;

FIG. 4 is a perspective view of the valve retainer for the straightvalve;

FIG. 5 is a perspective view of the valve member;

FIG. 6 is an end view of the valve member;

FIG. 7 is a perspective view of an alternative valve member; and

FIG. 8 is a perspective view of an alternative valve member.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE PRESENT INVENTION

Referring first to FIGS. 1 and 2, there is shown a valve member 10manufactured in accordance with the present invention and designed tocontrol the flow of fluid through a valve 12. As will be subsequentlydescribed, the valve member 10 is manufactured with sufficient strengthand rigidity to withstand the torque associated with manipulation of thevalve member 10 and with sufficient pliability and resiliency to preventfluid leakage. These dual material properties provide an efficient andeffective means of controlling fluid flow through the valve 12. Thevalve member 10 of the present invention will be described inconjunction with an angled valve (FIG. 2) and a straight valve (FIG. 3).The operation and properties of the valve member 10 are similar for bothtypes of valves.

The valve 12 includes a valve body 14 having a housing chamber 16 forreceiving the valve member 10. The valve body 14 includes an inlet 18preferably connected to a fluid source and an outlet 20 connected to aplumbing fixture such as a riser which connects to a faucet (not shown).The valve 12 is designed to control the flow of fluid from the source tothe fixture. In the angled valve 12, the inlet 18 and outlet 20 aredisposed at a right angle to each other. An end wall 22 of the valvebody 14 includes an aperture 24 through which the valve member 10extends as will be subsequently described. The housing chamber 16 of thevalve body 14 has a substantially cylindrical configuration with aninterior surface 26.

The valve member 10 is rotatably received within the valve body 14 tocontrol the flow of fluid therethrough. In a preferred embodiment of thepresent invention, the valve member 10 is formed of two components: arigid valve stem 28 to withstand the torque applied to the valve member10 and a more elastic valve sleeve 30 for improved fluid sealing.

The valve stem 28 has a substantially cylindrical portion 32 designed toengage a valve handle 34 for manipulation of the valve member 10. Thevalve handle 34 may matingly receive the cylindrical portion 32 of thevalve stem 28 and may be secured to the valve stem 28 such as by afastener 36 a press fit. The valve stem 28 extends through the aperture24 of the end wall 22. In a preferred embodiment, the valve stem 28includes at least one spline 38 to aid in the transmittal of rotation tothe valve member 10. The valve stem 28 also includes a base portion 40with a radially extending flange 42 and a tooth 44 to which the valvesleeve 30 is attached.

Preferably, the valve sleeve 30 is molded directly to the valve stem 28in a multi-shot molding operation. However, the components could beattached using other well-known methods including insert molding,staking, ultrasonic welding, vibration and any other known mechanicaland thermal-mechanical processes. The end result is a valve member 10formed of two different materials to create a rigid stem 28 and anelastic sleeve 30 for use in a stop valve. In the preferred method, thesleeve 30 is first molded of a softer elastic material. Thereafter, amore rigid material is used to mold the valve stem 28. Of course, it isto be understood that the components of the valve member 10 could bemolded in reverse order. During the molding process, the sleeve 30 ismolded around the base portion 40 of the valve stem 28 to create amaterial bond between the valve sleeve 30 and the valve stem 28. Theradial flange 42 and tooth 44 of the stem 28 provide increased surfacearea and mechanical interlock for bonding of the components.

The valve sleeve 30 has a substantially cylindrical cross-sectionalconfiguration with an outer surface 46 closely conforming to theinterior surface 26 of the valve body 14. In a preferred embodiment, thevalve sleeve 30 is formed with a discrete barrel configuration having aslightly larger diameter along the midsection in order to seal withinthe valve member 14, The valve sleeve 30 could also have a bulge orprotrusion 45 to seal the area around the port 50 against the valve body14. The valve sleeve 30 is formed with an inner fluid chamber 48 open atone end for communication with the inlet 18 of the valve body 14. Anoutlet port 50 is formed in the wall of the valve sleeve 30 forselective communication with the outlet 20 of the valve member. Formedin the exterior surface 46 of the valve sleeve 30 is at least oneannular sealing lip 52 which engages the surface 26 of the valve body 14to prevent fluid leakage past the valve stem 28. An O-ring seal membermay be used in place of the annular sealing lip 52 to control fluidflow. The elastic properties of the valve sleeve 30 improves sealingwithin the valve body 14 as the valve sleeve 30 is pressurized. Thefluid pressure within the fluid chamber 48 pushes the wall of the valvesleeve 30 outwardly against the inner surface 26 of the valve body 14 toprevent fluid leakage between the valve sleeve 30 and the valve body 14.

The valve stem 28 may also accept an additional back-up seal 51 orO-ring which sealingly engages the inner wall 52 of the valve body 14.The additional back-up seal 51 prevents contaminants from entering thevalve body 14 through the aperture 24 which could compromise theoperation of the valve 10.

In the straight valve 112 shown in FIG. 3, the valve member 110 isreceived within the valve body 114 such that the fluid flowstransversely through the valve member 110. In order to maintain thevalve member 110 within the valve body 114, a retainer ring 160 iscoaxially mounted to the valve member 110 proximate the junction of thevalve stem 128 to the valve sleeve 130. The retainer ring 160 (FIG. 4)includes an annular locking flange 162 designed to lockingly engage thevalve body 114. In this manner, the valve member is prevented from beinginadvertently pushed through the aperture 124 of the valve body 114. Theretainer ring 160 includes a secondary flange 164 which forms an annularpocket 166 for receiving an O-ring seal 168.

The back-up seal 151 sealingly engages the inner wall 152 of the valvebody 114 to prevent contaminants from entering the valve body 114. Theretaining shoulder 154 supports the seal 151 against the stem 128. AnO-ring seal 153 is supported within the annular pocket 166 formed on theretainer ring 160.

Formed in the outer surface 146 of the valve sleeve 130 is a pressuregroove 170 in communication with the inlet port 172 of the valve sleeve130 in the closed position. The pressure groove 170 maintains pressurewithin the inner fluid chamber 148 prior to opening of the valve 112 inorder to pressurize the valve sleeve 130 outwardly against the interiorsurface 126 of the valve body 114. The valve sleeve 130 essentiallybulges outwardly to sealingly engage valve body and improve theoperation of the valve 112.

Alternative embodiments of the valve member (210,310) are shown in FIGS.7 and 8. In these embodiments, a simple aperture 270 or asemi-elliptical aperture 370 facilitates fluid communication with theinner fluid chamber 248,348. The opening 270,370 communicates with theinlet 118 in the closed position to keep the interior of the valvemember 210,310 pressurized against the valve body. The opening 270 maybe any configuration which allows fluid communication with the innerchamber.

The valve body 14 is preferably formed of an extruded brass which issubsequently machined to form the required bores and openings.

The control sleeve 30 can be made from a thermoplastic material byinjection molding, liquid or reaction injection molding or any othersuitable process for forming thermoplastics such as compression moldingor rotomolding. Suitable thermoplastic materials for the control sleevemay include but are not limited to ABS, polypropylene, polycarbonate,polystyrene, nylon, polyester such as PET or PBT. Thermo set elastomermaterials may also be used including but not limited to EPDM, Nitrile,Viton, Buna N or Neoprene. More preferable materials suitable for thecontrol sleeve 30 include the family of materials known as thermoplasticelastomers including but not limited to the family of material under thetradename of Santoprene from AES Corp. such as Santoprene 243-40. Astill further material may be from the family of thermoplastic silicatesknown as TPSIV. Other thermal plastic elastomers such as COPE, COPA orSEBS may be used. To achieve the proper torque range when the controlsleeve 30 is rotated, the materials described above may be blended withany known internal lubricating agents such as PTFE powder, silicone oil,PTFE lubricants or a fatty acid. Alternatively, to facilitate therotation of the control sleeve 30, the control sleeve 30 may be coatedwith a suitable material such as a lubricating agent. Any suitablebarrier resistant coating material may be used as an agent on the sleeve30.

The stem 28 can be formed of a metal or durable plastic material in abroad range of thermoplastics including but not limited topolypropylene, polycarbonate, ABS, PET, PBT, nylon, PPO/HIPS blend. Toachieve a desired stiffness in the resulting stem 28, the thermoplasticmay be filled with glass fiber or any suitable mineral fillers such astalc, or a mixture of the glass fiber and mineral filler. A preferablefilled thermoplastic is glass-fiber filled polypropylene; the glassfiber content may range from 0 to as high as is allowed by the processused to shape the stem 28. Regardless of the choice of thermoplastic,the material must be such that the resulting stem possesses properresilience to permit its assembly to the valve body 14 in the mannerdescribed above.

The stem 28 and control sleeve 30 may be molded as one integrated pieceusing one suitable material as described above. Preferably, the stem 28and control sleeve 30 are molded sequentially in a two-shot moldingprocess wherein the sleeve is first molded with a lower modulus materialsuch as a thermoplastic elastomer as the first shot, followed by asecond injection of a high modulus material such as a 30% glass-fiberfilled polypropylene, to form the integrated stem and control sleeveplastic valve as described above. The interface between the first andsecond shot can be of any design as long as it allows the transfer oftorque from the handle 34 and the stem 28 to the control sleeve 30.

In this fashion, the connection between the handle 34 and the stem 28provides for the transfer of increased torque to overcome any long termmineral build-up or other deposit that may adhere the control sleeve 30within the valve body or overcome any increased friction due to anybulging of the resilient control sleeve within the outlet port asdescribed above.

The ability to significantly increase the maximum torque transfer allowsthis construction of a valve with the known desirable materials to moreuniversally accepted, particularly in geographic areas where hard waterwith various minerals are the norm.

Furthermore, the valve with the improved stem connection can beconfidently used in lines where the interim between using the shut offvalve may be many years which may allow for a substantial build up ofdeposits that may otherwise bind the valve in the open position.

The manufacturing process yields an efficient molded valve member tocontrol the flow through a valve. The two-shot molding process forms avalve member having a hard plastic shank or stem and a flexible plasticbarrel. Alternatively, the stem may be formed or machined of brass andthe flexible plastic barrel overmolded onto the stem. In a preferredembodiment, the shaft profile consists of three splines in order totransfer the torque applied to the handle to the valve member. The valvecylinder includes lip seals engaging the inner surface of the valve bodyto prevent leakage. To eliminate longitudinal movement of the valvemember in the straight valve, the retainer ring is used to hold thevalve cartridge within the valve body.

The foregoing detailed description has been given for clearness ofunderstanding only and no unnecessary limitations should be understoodtherefrom as some modifications will be obvious to those skilled in theart without departing from the scope and spirit of the appended claims.

1-10. (canceled)
 11. A valve for controlling fluid flow between a fluidinlet and a plumbing fixture, said valve comprising: a valve body havinga housing chamber with an inlet port in communication with the fluidinlet and an outlet port in communication with the plumbing fixture,said valve body including an aperture; a valve member rotatably receivedwithin said valve body, said valve member including: a valve stemextending through said aperture of said valve body to facilitatemanipulation of said valve member within said valve body, said valvestem including an upper stem portion extending through said aperture andan increased diameter base portion, said valve stem having asubstantially rigid material property to withstand axial twisting ofsaid upper stem portion during manipulation of said valve member; and avalve sleeve separately molded to said base portion to materially bondsaid valve sleeve to said valve stem such that said valve memberincludes distinct valve sleeve and valve stem whereby manipulation ofsaid valve stem is transmitted directly to said valve sleeve, said valvesleeve including an inner chamber and an outlet port, said valve sleevehaving elastomeric properties less rigid than said valve stem tofacilitate expansion under fluid pressure within said inner chamber forimproved sealing within said housing chamber of said valve body; and ahandle connected to said upper stem portion of said valve stem forselective manipulation of said valve member within said valve body. 12.(canceled)
 13. The valve member as defined in claim 11 wherein saidupper stem portion of said valve stem includes a plurality oflongitudinal splines, said cylindrical upper stem portion adapted toreceive a handle to facilitate manipulation of said valve member. 14.(canceled)
 15. The valve member as defined in claim 11 wherein saidvalve sleeve has a substantially cylindrical configuration with an outersurface conforming to an interior surface of the valve body, said valvesleeve having elastic properties such that fluid pressure within saidsleeve chamber moves said outer surface into sealing contact with theinterior surface of the valve body.
 16. The valve member as defined inclaim 15 wherein said valve sleeve includes at least one annular sealinglip engaging the interior surface of the valve body.
 17. The valvemember as defined in claim 15 and further comprising a pressure openingformed in said outer surface of said valve sleeve and in fluidcommunication with said sleeve chamber.
 18. The valve member as definedin claim 17 wherein said pressure opening is an aperture formed in saidwall of said valve sleeve.
 19. The valve member as defined in claim 17wherein said pressure opening is a groove formed in said outer surfaceof said valve sleeve and in communication with the interior of saidvalve sleeve.
 20. The valve member as defined in claim 13 and furthercomprising a retainer ring coaxially mounted to said valve stem andvalve sleeve, said retainer ring selectively engageable with the valvebody to lockingly retain said vale member within the valve body.
 21. Avalve member adapted to be rotatably received within a valve body tocontrol the flow of fluid between an inlet and an outlet of the valvebody, said valve member comprising: a valve stem having an upper stemportion extending from the valve body to facilitate manipulation of saidvalve member within the valve body and an enlarged diameter baseportion, said valve stem having a substantially rigid material propertyto prevent torsional distortion of said upper stem portion upon rotationof the valve body; and a valve sleeve molded around to encapsulate atleast a portion of said base portion of said valve stem to materiallybond said valve sleeve to said valve stem such that manipulation of saidvalve stem is transmitted to said valve sleeve through said base portionof said valve stem, said valve sleeve including at least one annularsealing lip engaging the interior surface of the valve body and an innerchamber with an outlet port, said valve sleeve being distinctly formedfrom said valve stem and having elastomeric properties less rigid thansaid valve stem to facilitate expansion under the fluid pressure withinsaid inner chamber for improved sealing within the valve body.
 22. Thevalve member as defined in claim 21 and further comprising anelastomeric retainer ring coaxially mounted to said valve stem and valvesleeve, said retainer ring selectively engageable with the valve body tolockingly retain said valve member within the valve body.